Dual balloon catheter

Abstract

Methods and devices for bonding a balloon assembly, such as a balloon assembly including an inner balloon and an outer balloon, to a catheter shaft are disclosed. In some cases, a proximal waist of the inner balloon may be bonded to an interior surface of an outer tubular member of the catheter shaft and a proximal waist of the outer balloon may be bonded to an exterior surface of the outer tubular member. In other cases, the proximal waist of the inner balloon may be bonded to a reduced diameter portion of the outer tubular member of the catheter shaft and the proximal waist of the outer balloon may be bonded to the outer tubular member, such as a non-reduced outer diameter portion of the outer tubular member.

What is claimed is: 
     
       1. A medical device comprising:
 a catheter shaft including a first tubular member and a second tubular member, the first tubular member including a proximal region, a distal region, and a lumen extending therethrough, the second tubular member including a proximal region, a distal region, and a lumen extending therethrough, the second tubular member being at least partially disposed within the lumen of the first tubular member, wherein the distal region of the second tubular member is configured to extend distally of the distal region of the first tubular member; 
 a first balloon including a proximal waist coupled to an inner surface of the first tubular member; and 
 a second balloon disposed about the first balloon and including a proximal waist coupled to an outer surface of the first tubular member; 
 wherein the first tubular member includes one or more conduits in fluid communication with a space between the first balloon and the second balloon, wherein the first tubular member includes one or more radially extending openings for fluidly connecting the one or more conduits with the space between the first balloon and the second balloon. 
 
     
     
       2. The medical device of  claim 1 , wherein the first balloon includes a distal waist coupled to the second tubular member, and wherein the second balloon includes a distal waist coupled to the distal waist of the first balloon and/or the second tubular member. 
     
     
       3. The medical device of  claim 1 , wherein the second tubular member lumen is a guidewire lumen. 
     
     
       4. The medical device of  claim 1 , wherein the catheter shaft defines an exhaust lumen between the inner surface of the first tubular member and an outer surface of the second tubular member. 
     
     
       5. The medical device of  claim 1 , wherein the catheter shaft defines a supply lumen, the supply lumen including a proximal end configured to be coupled to a fluid source for receiving a cooling fluid and a distal end in fluid communication with a chamber defined by the first balloon. 
     
     
       6. The medical device of  claim 1 , wherein a distal end of the one or more conduits is prevented from fluidly communicating with a chamber defined by the first balloon. 
     
     
       7. The medical device of  claim 6 , wherein the proximal waist of the first balloon is coupled to the first tubular member distal of the opening and the proximal waist of the second balloon is coupled to the first tubular member proximal of the opening. 
     
     
       8. The medical device of  claim 1 , wherein the proximal waist of the first balloon is coupled to the inner surface of the first tubular member at a point distal of the one or more openings. 
     
     
       9. A medical device comprising:
 a catheter shaft including a first tubular member and a second tubular member, the first tubular member including a proximal region, a distal region, and a lumen extending therethrough, the second tubular member including a proximal region, a distal region, and a lumen extending therethrough, the second tubular member being at least partially disposed within the lumen of the first tubular member, wherein the distal region of the second tubular member is configured to extend distally of the distal region of the first tubular member, wherein the distal region of the first tubular member includes a first outer diameter portion and a second reduced outer diameter portion; 
 a first balloon including a proximal waist coupled to the reduced outer diameter portion of the first tubular member; and 
 a second balloon disposed about the first balloon and including a proximal waist coupled to the first tubular member; 
 wherein the catheter shaft includes one or more conduits in fluid communication with a space between the first balloon and the second balloon, wherein the first tubular member includes one or more openings fluidly connecting the one or more conduits with the space between the first and second balloons, the one or more openings extending through the first tubular member in the first outer diameter portion, such that the first outer diameter portion extends distal of the one or more openings. 
 
     
     
       10. The medical device of  claim 9 , wherein the first balloon includes a distal waist coupled to the second tubular member, and wherein the second balloon includes a distal waist coupled to the distal waist of the first balloon and/or the second tubular member. 
     
     
       11. The medical device of  claim 9 , wherein the second balloon is coupled to the first tubular member proximal of the reduced outer diameter portion. 
     
     
       12. The medical device of  claim 9 , wherein the reduced outer diameter portion of the first tubular member is formed by bonding a distal extension to the first tubular member. 
     
     
       13. The medical device of  claim 9 , wherein the second tubular member lumen is a guidewire lumen. 
     
     
       14. The medical device of  claim 9 , wherein the catheter shaft defines an exhaust lumen between the inner surface of the first tubular member and an outer surface of the second tubular member. 
     
     
       15. The medical device of  claim 9 , wherein the catheter shaft defines a supply lumen, the supply lumen including a proximal end configured to be coupled to a fluid source for receiving a cooling fluid and a distal end in fluid communication with a chamber defined by the first balloon. 
     
     
       16. The medical device of  claim 9 , wherein a distal end of the one or more conduits is prevented from fluidly communicating with a chamber defined by the first balloon. 
     
     
       17. A method of bonding a first balloon and a second balloon to a catheter shaft, the method comprising:
 providing a catheter shaft including an outer tubular member and an inner tubular member, the catheter shaft including one or more conduits; 
 bonding a proximal waist of the first balloon to the outer tubular member of the catheter shaft; 
 bonding a distal waist of the first balloon to the inner tubular member; 
 flaring a proximal waist of a second balloon; 
 positioning the second balloon with the flared proximal waist over the first balloon and the catheter shaft; 
 bonding the flared proximal waist of the second balloon to the outer tubular member; and 
 bonding a distal waist of the second balloon to the inner tubular member and/or the distal waist of the first balloon, wherein a space between the first balloon and the second balloon is in fluid communication with the one or more conduits, wherein the outer tubular member includes one or more openings fluidly connecting the one or more conduits with the space between the first and second balloons, the one or more openings extending radially through an outer wall of the outer tubular member such that the outer wall extends distal of the one or more openings. 
 
     
     
       18. The method of  claim 17 , wherein bonding the proximal waist of the first balloon to the outer tubular member of the catheter shaft included bonding the proximal waist of the first balloon to an inner surface of the outer tubular member. 
     
     
       19. The method of  claim 17 , wherein the outer tubular member includes a reduced outer diameter distal portion spaced apart distally from the one or more openings, and wherein bonding the flared proximal waist of the second balloon to the outer tubular member includes bonding the flared proximal waist of the second balloon to the reduced outer diameter distal portion of the outer tubular member.